Case | The “Tendons and Bones” of a Robotic Dog: Joint Protection and Performance Optimization in Extreme Environments
01. It’s Not Enough to “Move”—It Must Move Stably and Endure
The Arctic K9 Robotics team in Finland is developing a quadruped robotic dog designed for extreme environment inspections—Frost-Runner.
It must patrol snow-covered terrain at -30°C, slippery rocks, and wind-swept ports for extended periods, maintaining agility while ensuring its joint modules function reliably in mud, ice, and dust.
The real challenge is not just to make it move, but to make it keep moving.
The most critical components are the protective housing and bearing seat of the joint drive module, which determine the robotic dog’s durability and energy efficiency during continuous six-hour missions.
02. From “Laboratory Perfection” to “Field Survival”
Arctic K9’s initial design performed excellently in the lab: fully sealed titanium housings with imported fluororubber seals provided outstanding water and dust resistance.
However, during low-temperature shock tests, the fluororubber seals hardened and cracked, allowing water ingress that froze, causing torque losses up to 20%.
Worse, the titanium housings—though strong—required long machining times, high costs, and slow delivery, unsuited to the team’s testing pace.
The team realized that in extreme environments, design must balance strength and toughness, or even the most perfect lab performance won’t hold in the field.
03. From “Machined Parts” to “Environment-Adapted Solution”
After an industry introduction, Arctic K9 engaged Leanplans (立谱智造).
We received their CAD files and ran a preliminary DFM evaluation using our AI Multi-Agent system. Our engineering team then held remote sessions with the client, focusing on weather resistance and maintainability.
We proposed three core optimizations:
1️⃣ Dual-Layer Armor: Metal + Engineering Plastic
- Outer layer: high-impact PEEK (injection-molded), resistant to mud, water, and low-temperature shocks.
- Inner layer: 17-4PH stainless steel precision casting for rigidity and corrosion resistance.
2️⃣ Low-Temperature Sealing System
- Replaced fluororubber with polyurethane elastic seals (flexible down to -60°C).
- Added PTFE coating at seams to reduce friction and prevent binding.
3️⃣ Modular Quick-Release Structure
- Split bearing seat with stainless steel threaded inserts for on-site tool-free disassembly.
- Reduced maintenance time by 70%.
04. Speed Isn’t About “Rushing”—It’s About “Reducing Validation Time”
Once the design was finalized, we used three parallel production processes for different components to meet delivery schedules:
- Outer housing (PEEK): high-temperature injection molding + anti-icing coating
- Inner support (17-4PH stainless steel): precision casting + high-speed CNC finishing, heat-treated for strength
- Bearing seat: five-axis CNC machining, positioning accuracy ±0.015 mm
- Seals: custom polyurethane molding
The full set of samples was delivered within 10 working days. Arctic K9 tested the robotic dog continuously in snow and ice for 96 hours, achieving:
- Joint torque stability +18%
- Energy consumption -9%
- Maintenance efficiency doubled
05. It’s Not Just About Moving—It’s About Lasting in Harsh Environments
For extreme-task robotic dogs, components aren’t meant to merely function—they must endure the harshest conditions.
Leanplans not only delivered parts but contributed to protection strategy, material selection, and maintainability, boosting both performance and durability.
We are now providing one-stop services from structural review to multi-process prototyping for quadruped robots, specialized inspection devices, and rescue robots worldwide.
If your project faces extreme environment design challenges, send us your CAD files—your next robotic dog could run longer and more reliably.
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